Download Operating Instructions for Angle Heads

Operating Instructions
for Angle Heads
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
OPERATION INSTRUCTION ANGLE HEADS
Introduction
Dear Customer,
We would first like to thank you for your purchase from Mimatic-Zettl.
You have chosen a high quality product that will only improve your manufacturing
processes.
The following instructions will help you to better understand and get to know your angle
head, and also explain the best practices on it’s use.
Please pay attention to the following important secuirty – and warnings, so your angle
head will remain trouble-free.
We would be happy to supply you with any of our other products from both our standard
and custom programs. For further information please contact Mimatic’s home office or
any of our global sales representatives.
All rights reserved:
mimatic Zettl GmbH – Westendstraße 3 – 87488 Betzigau
These directions - or any extracts from – may be shared with a third party, only with the
expressed or written agreement, from mimatic Zettl GmbH.
Any who reproduce, distribute or store this material on any medium without the expressed
approval from Mimatic Zettl GmbH, will be fully prosecuted under the claimed copy right
laws.
We reserve the right to make any technical changes and improvements that may not be
reflected in this handbook.
Responsible author for the contents of these instructions:
mimatic Zettl GmbH – Westendstraße 3 – 87488 Betzigau
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 2
OPERATION INSTRUCTION ANGLE HEADS
Contents
1
2
Concept Definitions
Basic Safety Guidlines
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Recommended Use
Arbitrary Reconstruction
Symbol Definitions
Product Awareness
Qualified Operators
Responsibilities of Operator
Protective Equipment
Operational Hazards
2.8.1
2.8.2
2.9
2.10
3
Intended Use
Warranty
Transport and storage
3.1
3.2
4
Mechanical Dangers
Excessive Warming
Protecting the tool during transport
Storage
Set up and Installation
4.1
Adjusting the Angle Position
Seite
4
5
5
5
6
7
7
7
7
8
8
8
9
9
10
10
10
11
11
5
Coolant Supply
12
6
Initial Operation and Application
13
7
Issues and Troubleshooting
14
8
Maintenance and Repair
15
15
16
8.1
8.2
Maintenance
Repair
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 3
OPERATION INSTRUCTION ANGLE HEADS
1
Concept Definitions
Product specific descriptions are explained in the below drawing.
For custom angle heads, you will also receive a dimensional drawing, which
provides specific product descriptions.
Shaft Type and Size
“0” - Point
Locking Mechanism
360° Scale
(continuously adjustable)
Torque Support
Standard per ISO 9524
Indexing Pins
(4 x 90°)
Housing
Tool Clamping System
Collet Chuck “ER” or
modular Quick-Change-System “mi”
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 4
OPERATION INSTRUCTION ANGLE HEADS
2
Basic Safety Instructions
These operating instructions should always be kept in the same place where the
angle head is stored.
The following policies provide safety instructions to prevent accidents and also
optimize the use of the angle head.
2.1 Recommended Use
The angle head is designed to be used in machining centers, for example on
milling, drilling and tapping applications.
Any non-approved usage of the angle head can result in a void of the
warranty and Mimatic will not be held responsible.
Always observe these best practices for the angle head that are explained in
this manuel:
o Set-up and maintenance of the angle head.
o Not exceeding the recommended running time.
o Observing max. RPMs when running tool with/without
coolant.
o Also, the limits of the clamped cutting tools.
More precise information on the performance of the angle head can be
found on the provided technical drawings.
2.2 Arbitrary Modification
Do not modify or re-build the angle head without authorization from
Mimatic. If the user or owner decides to make any modifications or attempts
to repair or re-build the tool, the warranty can be voided if damage occurs
from improper usage.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 5
OPERATION INSTRUCTION ANGLE HEADS
2.3 Symbol Explination
In this instruction manuel, the following symbols are frequently used. Please
pay attention to their following explinations:
DANGER:
DANGER
This symbol means there is a risk or
danger to the operator.
Not adhering to this recommendation
can result in serious consequences to
both the angle head and the health of
the operator.
Recommendation:
Under this symbol you will find
recommendations, application tips and
useful Information.
Recommendation
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 6
OPERATION INSTRUCTION ANGLE HEADS
2.4 Product Damage
Too high of a noise level or too high of a temperature when the angle head
is run, can be caused by bearing or gear damage, or if the tool has not
been properly set-up in the machine.
In chapter 7 you will find tests and troubleshooting to address any symtoms
of damage. Please inform Mimatic immediatly of any issues. If the problem
still exists after you have performed the troubleshooting, do not run the tool
as serious damage could occur to the user, angle head or machine.
2.5 Qualified Operators
Only qualified operators may run the angle head. The operator must
understand the proper set-up, service, maintence and useage of the tool.
Those who are learning how to use the tool must always do so under the
supervision of a qualified operator.
2.6 Responsibilities of the Owner
The owner is responsible for informing all operators of the angle head about
the safety instrusctions and best practices. The owner is also responsible for:
Briefing all operators on the safety instructions and prevention of
accidents before the operator begins using the angle head.
Making sure the angle head is set-up only on a machine that conforms
to all safety regulations.
2.7 Protective Equipment
Always wear safety shoes, protective glasses and ear
protection. When lifting or transporting the angle head, if
needed, wear extra back support to avoid injury.
DANGER
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 7
OPERATION INSTRUCTION ANGLE HEADS
2.8 Operational Hazards
2.8.1 Mechanical Hazards
DANGER
DANGER:
Using too high pressure or defective seals can cause
coolant to leak into the angle head. Regularly test the
coolant pressure from the machine and always pay
close attention to the tool to make sure no leakage is
occuring.
WARNING:
When using the angle head, make sure that the safety
features of your machine are on. Also make sure that
the cutting tool is properly clamped.
WARNING
2.8.2 Heating of the Angle Head
DANGER
DANGER:
During use of the angle head, the acceptable
temperature of the tool is less then 75°C. Always wear
saftey gloves when moving or switching out the angle
head.
DANGER:
Always keep the angle head away from flammable or
explosive materials.
DANGER
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 8
OPERATION INSTRUCTION ANGLE HEADS
2.9 Intended Use
CAUTION:
If the head is not used for it’s intended applications,
harm may come to the operator, angle head or the
machine itself.
CAUTION
2.10 Warrantee
Warranties and liability claims are void if the operator does not adhere to
the following points:
Improper usage of tool.
Betreiben des Winkelkopfes bei defekten und/oder nicht
funktionsfähigen,
bzw.
ausgeschalteten
Sicherheitsund
Schutzeinrichtungen
Disregard of the directions for use including: storage, maintence and
set-up of the angle head.
Making alterations to the angle head without consent or approval from
Mimatic GmbH.
Exceeding the operational parameters of the angle head.
Not properly monitoring the tool while it is in use.
Crash resulting from an unapproved repair of tool.
Crash resulting from the introduction of foreign parts into the angle
head.
For more detailed warranty information, please visit our website under
„Verkaufs- und Lieferbedingungen“, and the information can be
downloaded from there.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 9
OPERATION INSTRUCTION ANGLE HEADS
3
Transportation and Storage
Please read the following best practices on transportation and storage of your
angle head. Even slight damage to the angle head can make it unusable or cause
damage to the machine when used.
If you are going to be transporting or storing the angle head for an extended
amount of time, please consult with Mimatic or your sales representative first.
3.1 Protecting the tool during transport
When transporting, make sure to protect the following areas of the tool:
Drive shaft
Any supports, locking mechanisms and surfaces that could be damaged.
Collet
3.2 Storage
If the angle head is going to be stored for an extended amount of time,
please pay attention to the following points:
Store only in a dry space.
Make sure to oil the tool.
Protect the surfaces of the tool from damage with proper packaging
material.
After a long storage time, make sure to clean the tool before it is put into
use.
Before the tool returns to service, make sure to see if the locking
mechanism is working properly and test make sure the drive gear is
working without obstruction.
DANGER
COLLISIONS
When the angle head is put into use on a new
machine, or if the tool has not been used on the same
machine for some time, always test the swing
clearances to make sure no collision or crash will
occur.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 10
OPERATION INSTRUCTION ANGLE HEADS
4
Set-up and Installation
The basic set-up of the angle head can be found in chapter 1. For all applications
of the angle head please pay attention to the technical features and the product
specific drawings for your tool.
The boring spindle(s) come equipped with high-quality spindle bearings. All drive
components are build for high speed RPMs.
Our angle heads can be fitted with variuos tool spindles depending on the
customer’s needs.
CAUTION – COLLISION RISKS
Missuse can cause damage to both the machine and the
angle head itself.
CAUTION
Important: the angle heads are generally designed for a
specific machine type or specific manufacturer.
Perform a collision test with a clamped tool in the
anlge head before each new use.
4.1 Adjusting the Angle Position
The anlgle head is 360° rotatable.
Loosen or unlock the 6 nuts,
then adjust the tool to the desired angle.
You can easily position the angle head every
90°.
With the help of the indexing pin (when all 6
nuts are loosend and the pin pulled out) the angle head automatically stops
in four 90° intervals.
After the desired angle has been set-up and before the use of
the angle head, make sure the 6 nuts have been fully
tightened ! Tightening torque 20 – 22 Nm !
CAUTION
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 11
OPERATION INSTRUCTION ANGLE HEADS
You can also set-up the angle position
for the machine side by using the gripper
keyway. Simply loosen the 6 thread pins.
Then adjust to the desired location.
After the desired angle has been set-up and before the use of
the angle head, make sure the 6 thread pins have been fully
tightened ! Tightening torque 3 Nm
CAUTION
5
Coolant Supply
For external coolant:
Open the fish eye or remove the screw plug and install the appropiate screw joint
along with the coolant pipes.
Für use with internal coolant:
CAUTION – COOLANT CONTENTS
Missuse kann cause tool damage.
Coolant may not contain particles bigger than 15 µm.
CAUTION
CAUTION – COOLANT LEAKAGE
Coolant leakage can cause serious damage. Small amounts
of leakage are tolerable. Leakage in large quantities (i.e.
continious flow of coolant) suggests defective seals and
damage will occur to the angle head.
CAUTION – COOLANT CONTAMINATION
Use of contaminated coolant can cause damage. Pay
attention to all directions from your coolant supplier.
Regularly clean and remove any residue. Be sure to wear
protective gloves.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 12
OPERATION INSTRUCTION ANGLE HEADS
6
Initial Operation and Application
Check to make sure the tool has not been damaged during transport. If there is
apparant damage from transportation, DO NOT operate the tool. Immediately
inform your sales representative of the damage.
Important
IMPORTANT INFO:
Proof all of the provided drawings and data sheets against
the following criteria:
Proper machine adaptor
Enough room in turret for angle head
Enough room in tool magazine for angle head
Angularity of the angle head
Check the tool weight against the max. allowed weight
of the tool changer
Check The Following Procedures Before Tool
Operation Begins:
Make sure no collisions can occur in the tool
magazine !
Make sure no collisions occur when the tool is
automaticaly switched !
Make sure there is nothing blocking the path of
the angle head that could cause a collision
during automatic change !
Make sure all adaptors are properly set-up !
Make sure there are no physical defects on the
angle head !
Always keep in mind when tool is operating:
Gear Ratio
Clamping chucks properly used
Make sure clamped tools are all set-up properly
to perform within tolerance
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 13
OPERATION INSTRUCTION ANGLE HEADS
7
Issues und Troubleshooting
HINWEIS:
Malfunctions or misuse of the angle head can cause a shorter
life span and a reduction of accuracy.
If there is ever an issue that arises with you angle head, please
contact your sales representative.
Issue
Too high noise level.
Excessive heating.
Test
Solution
Inspect the length of the locking
devise and if necessary, the
base support.
Inspect the length of the locking
devise and if necessary, the
base support.
Length of the locking devise and
base
support
should
be
inspected by Mimatic GmbH.
Length of the locking devise and
base
support
should
be
inspected by Mimatic GmbH.
Inspect the angle head for Complete maintence and repair
leakage und loss of lubrication. by Mimatic GmbH.
Excessive heating on angle Inspect the pathway of the Flush the coolant pathways.
head with internal coolant.
coolant bores.
Is coolant being received from Make sure the coolant pathways
machine?
are fully open.
Dimensionel – or form defect on Inspect the tool for too much Switch out used tool.
the work piece.
wear.
Tool drifiting due to too much Reduce clamping force, feed
clamping force or too high of a rate or any other necessary
application parameters.
feed rate.
Are there concentricity flaws?
Make sure the tool is properly
clamped.
Too great of variation between Measure the angularity and
adjust
the
angle
head
finished workpieces?
accordingly.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 14
OPERATION INSTRUCTION ANGLE HEADS
8
Maintenance & Repair
Regularly clean the surfaces of the angle head with a cloth and for the hard to
reach places, use a small brush. To increase the life of the angle head, we
recommend that after 1 year of use, send the tool to Mimatic for a complete
maintenance and service check. .
If you replace the lubrication, please observe the following:
Lubrication – High Performance; Manufacturer KLÜBER Isoflex
NBU 15
Mimatic recommends that you regularly oil the angle head to prevent corrosion.
NOTE:
Disassembling the angle head – without the approval of
Mimatic can result in a forfeiture of the warranty!!
SERVICE:
If requested, Mimatic can perform a service test on your angle
head. We will disassemble the angle head, inspect, perform
maintenance and inform you if any replacement parts are
needed.
8.1 Maintenance
Recommendation – INCREASING THE LIFE OF THE TOOL
During the use of the tool it is recommended every 2 weeks to
inspect all moving parts and make sure the tool is running
smoothly. Remove all chips, coolant and dirt, to ensure that
all parts of the head are running without obstruction.
Remove any cleaning materials with pressurised air. This
insures that no particles will be caught in the tool and damage
to the seals will be avoided.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 15
OPERATION INSTRUCTION ANGLE HEADS
8.2 Repair
The bearings, gears and sealing elements naturally endure wear and tear.
This wear is dependent on:
How long and often the head is run.
How fast the tool is being run.
What type of application the tool is being used for.
Monitor the tool with the above criteria, so that any damaged part can be
detected early, and no permanent damage is caused to the head.
CAUTION
Repairs may only be performed by qualified personel. If you
decide to try and do a repair yourself, please contact Mimatic
for the recommended replacement parts.
CAUTION
CAUTION - COLLISION
After a repair has been made, make sure to perform a
collision test with a clamped cutting tool in the machine, to
avoid any crashes.
CAUTION – LUBRICANT AND HYDRAULIC FLUIDS
Always wear protective gloves when dealing with either of the
above mentioned.
Skin contact: wash with soap and rinse thoroughly with water.
Eye contact: Flush eyes thoroughly with water and contact
your doctor.
When swallowed: contact your doctor immediatly.
mimatic Zettl GmbH – Westendstraße 3 – D-87488 Betzigau
Tel. +49(0) 831 / 57 444 – 0 // Telefax +49(0) 831 / 57 444 – 90
[email protected] // www.mimatic-zettl.de
Page 16